Fives Pillard, leading engineers & suppliers of … · Fives Pillard 1 Novaflam® burner Return of experience Design criteria Fives Pillard, leading engineers & suppliers of combustion

Fives Pillard 1

Novaflam® burner

Return of experience

Design criteria

Fives Pillard, leading engineers & suppliers of combustion solutions

Fives Pillard 2

Novaflam® burner

Fives Pillard – March 2011 3

The NOVAFLAM burner

Burners with axial & swirl

channels adjustable at site

ROTAFLAM®

Addition of "slot effect"

ROTAFLAM® Version2

“Tailor-made" engineered design

Allows much easier adjustments

NOVAFLAM®

NEW PATENTS

EP 06.778673.1 of June 26,2006

EP 07.290663.9 of May 23, 2007

FR0852836 of April 28, 2008

FR2009/050593 of April 07, 2009

Main features :

(single air supply)

burner tips engineered

according to process data

From the ROTAFLAM… to the NOVAFLAM burner…


The NOVAFLAM burner

A MONOCHANEL BURNER : Axial and Radial air are supplied by a same burner channel

MORE EFFICIENT IN TERM OF IMPULSE AND SWIRL : Limited loss of pressure in the burner

EASY TO UNDERSTAND, TO USE, TO ADJUST : 2 parameters to be adjusted


The NOVAFLAM® burner

AXIAL AIR INJECTED IN THE FLAME BY HOLES

CONSTANT CROSS SECTION

ADJUSTEMENT BY PRESSURE

CONTROL

ADJUSTABLE RADIAL AIR ANGLE

NO NEED TO CHANGE RADIAL AIR

QUANTITY FOR FLAME SHAPING

VERY EASY TO ADJUST

FLAME WIDTH

COAL AND CENTRAL AIR CHANNELS :

IDENTICAL TO THE ROTAFLAM® RV2


The NOVAFLAM® : The new kiln burner

BY MOVING BACK THE RADIAL TIP, WE ADJUST THE FLAME WIDTH

BY CONTROLLING THE PRIMARY AIR PRESSURE, WE ADJUST THE BURNER IMPULSE

NEW PATENTS

EP 06.778673.1of June 26,2006

EP 07.290663.9 ofMay 23, 2007

FR0852836 of April 28, 2008

FR2009/050593 of April 07, 2009







OUR TYPICAL DESIGN CRITERIA:

MOMENTUM

4-5 N/MW : FO/ GAS (around 7-8 % PA, stoechiometric basis)

6-7 N/MW : COAL, PETCOKE, ANTHRACITE (around 9-10 % PA, stoech basis)

8-9 N/MW : HIGH ASF SUBSTITUTION (around 11-12 % PA, stoech. basis)

SWIRL

Usual : 0.10 < swirl < 0.3

AXIAL & RADIAL CROSS SECTION REPARTITION

%AXIAL / % RADIAL repartition from 50 / 50 to 70 / 30


IMPULSION AND SWIRL CALCULATION

SPECIFIC IMPULSE CALCULATION

AXIAL MOMENTUM (N) flame hardness Gx (N) = Q (kg/s) x Vout axial (m/s)

Gx total (N) = Gx axial (N) + Gx radial (N) + Gx central (N)

SPECIFIC MOMENTUM (N/MW) to compare burners with different output heat output

I total (N/MW) = Gx total (N) / P (MW)


IMPULSION AND SWIRL CALCULATION

SWIRL NUMBER CALCULATION

TANGENTIAL MOMENTUM (N) amount of swirl motion

Gt total (N) = Gx radial (N) x tan (α)α swirl angle on the radial tip

SWIRL NUMBER number without dimension for swirl characterization

Gt x Rg

SN = -------------------------

De x Gx

Rg : gyration radius of swirl channel

De : equivalent theoritical opening diameter giving with the same flow

the same momentum

)(3

)(222

33

rire

rirerg

)Gxm(

)QmrQma(2De

Fives Pillard 12

NOVAFLAM®

RECENTLY COMMISSIONNED:

NOVAFLAM WITH HIGH ASF SUBSTITUTION :

- Lumbres and Dannes, France

NOVAFLAM WITH HIGH ASF SUBSTITUTION :

- PHOENIX, Germany

NOVAFLAM WITH "DIFFICULT" KILN (RING FORMATION):

- HOLCIM Rochefort, France

NOVAFLAM FOR LARGE CAPACITY LINES :

- TPI SARABURI, Thaïland – 3 x 9000 TPD lines

NUMEROUS REFERENCES WITH LOW QUALITY COAL :

- In ASIA : 40 burners in operation

NOVAFLAM FOR INDIA:

- DARLAGHAT

NOVAFLAM FOR INDIA:

- SITUPARAM


HOLCIM LUMBRES , France

KILN

TYPE WET LINE

PROD.(TPD) 800

SEC. AIR (°C) 750

FUELS COAL

BURNER REPLACEMENT TARGET INCREASE IMPREGNATED SAW DUST %

HOLCIM LUMBRES

France

(January 08)


HOLCIM LUMBRES , France (commissioning in jan. 08)

CONFIRMED RESULTS

SAWDUST MULTIPIED x 2(limited by sawdust availibility)

Better kiln stability

Less primary air,

Burner tips are in perfect condition

BEFORE AFTER

BURNER

TYPE 3 CHANNEL NOVAFLAM

PA (%) 10 8-9

PA pressure (mbar) 220 130 - 170

Momentum (N/MW) 8 5 - 6


HOLCIM DANNES, France (commissioning Sept. 08)

KILN

TYPE LEPOL GRATE, SATELLITE COOLER

PROD.(TPD) 1 200

SEC. AIR (°C) 750

FUELSMIX COAL-PETCOKE+SLUDGE

IMPREGNATED SAWDUST / ANIMAL MEAL

SOLVENT

BURNER REPLACEMENT TARGET INCREASE IMPREGNATED SAW DUST %

HOLCIM DANNES

France

(September 08)


HOLCIM DANNES, France (commissioning Sept. 08)

BEFORE AFTER

BURNER

TYPE 3 CHANNEL NOVAFLAM

PA (%) 10 9

PA pressure (mbar) 220 130-180

Momentum (N/MW) 8 Around 6

CONFIRMED RESULTS

SAWDUST + 70 %(4T/h currently)

NO MORE RING FORMATION

LESS PRIMARY AIR


PHOENIX , Germany

KILN

TYPE DRY, GRATE COOLER

PROD.(TPD) 1 300

SEC. AIR (°C) 800

FUELSCOAL

FLUFF

BURNER REPLACEMENT TARGET MORE SIMPLE BURNER

PHOENIX

Germany

(February 10)


PHOENIX , Germany

BEFORE AFTER

BURNER

TYPE ROTAFLAM V2 NOVAFLAM

PA (%) 10 8-9

PA pressure (mbar)

350 / 250

Axial air fan 90 KW

Radial fan 52 KW

150-200

Common fan 90 KW

Momentum (N/MW) 8 4,5-6

Swirl 20° / ? 25° / 0.3

Electrical consumption (kW) 142 KW 90 KW

PROCESS

NOx

Urea consumption (kg/hr)

CO (ppm)

O2 Kiln inlet (%)

Kiln inlet temp. (°C)

470

150

0

5

852

420

70

0

5

816

CONFIRMED RESULTS

70 % FLUFF WITH A BURNER EASIER

TO OPERATE

Reduction by 50% of expensive waste oil

consumption to recover a weak kiln


Phoenix Germany: Electrical consumption

• Simulation in Germany

– Electrical Consumption

90 kW instead of 142 kW leads to a cost saving of about :

0.052 MW x 8000 h/year x 92 $/MWh (price - Germany -June 2008) = 38 300 $ / year ==>

30 000€/year

– CO2 Saving :

404 kg/CO2 /MWh (GHG Protocol -- Germany )

=> 404 * 0.052 * 8000 = 168,8 t CO2/year ==> only 14€/ton CO2 (current CO2 price)

==> 2 300 € /Year (Low)

– With the same operating condition the cost saving is about 32 000 € /Year.


Phoenix Germany: Electrical consumption

• If similar situation in Switzerland (high % hydro electricity => high electrical cost)

– Electrical Consumption

90 kW instead of 142 kW leads to a cost saving of about :

0.052 MW x 8000 h/year x 154 $/MWh (price EIA - Switzerland -June 2010) = 64 000 $ / year

==> 50 000 € /Year.

- CO2 Saving :

26 kg/CO2 /MWh (GHG Protocol - - Switzerland ) ==> 26 * 0.052 * 8000 = 10,8 t CO2/year ==>

only 14€/ton CO2 ==> 364 € (negligeable)

– With the same operating condition the cost saving is about 50 000 € /Year.


HOLCIM ROCHEFORT, France (commissioning april. 10)

KILN

TYPE LEPOL GRATE, SATELLITE COOLER

PROD.(TPD) 1 200

SEC. AIR (°C) 1000

FUELS

MIX COAL-PETCOKE+SLUDGE

IMPREGNATED SAWDUST / ANIMAL MEAL

SOLVENT

+ PYROLYSIS GAS

BURNER REPLACEMENT TARGETSUBSTITUE 20 % COAL BY PETCOKE

WITHOUT RING FORMATION

NOVAFLAM (ASF + COAL )

PYROLISIS BURNER


BEFORE AFTER

BURNER

TYPE ROTAFLAM NOVAFLAM

PA (%) stoec.bas 17,5 11,5-13

PA pressure (mbar) 300 (axial) / 170 (rad fan) 170- 220

Swirl number 0.06 0.05

Momentum (N/MW) 12 7 - 8,5

Estim .Elec cons. (kW) 80 45-60

EMISSIONNOx kiln inlet

(mg/Nm3@10%O2)800 800

CONFIRMED RESULTS

PROCESS MORE STABLE

Up to 30% COAL SUBSTITUTION,

FLAME MORE COMPACT

LESS PRIMARY AIR, 25-40 % LESS

ELECTRICAL CONSUMPTION



WHAT ABOUT THE NOx EMISSION ?

– If NOx isn't a major issue, burner optimisation (less primary air flow) is sufficient to

keep NOx at the same level than the ROTAFLAM



NOVAFLAM® LOW NOX DESIGN

If NOx is a major issue The NOVAFLAM can be specifically designed to reduce NOx

The NOVAFLAM LOW NOx applies the

following principles:

- Specific tip design

- Lower primary air flow

- High pulverized fuel concentration

- Minimum "slot" effect

First NOVAFLAM LowNox

in Kazakstan


Opinion of D.Mac Phail, plant manager :

" When compared to the ROTAFLAM burner, the implementation of the new NOVAFLAM

burner contributes:

– To allow using 30 % petcoke

– To improve kiln stability

– To achieve a flame centred in the kiln, with little impact from the Pyrolysis burner

located above it

– To have an easily adjustable burner, well mastered by the operators

– To reduce the primary air rate & electrical consumption "



TPI POLENE, Thailand, 3 Novaflam® 160 MW

KILN

TYPE DRY LINES (Kiln Diameter = 5.6 m)

PROD.(TPD) 8 500 - 9 000 (Max.)

SEC. AIR (°C) 1 100

FUELS COAL (24 T/h) / RDF (18 T/h)

BURNER REPLACEMENT TARGETHIGHER CLINKER QUALITY

FIRING FLUFF (NOT YET STARTED)


BEFORE AFTER

BURNER

TYPE OTHER'S NOVAFLAM

PA (%) 9 12.5*

PA pressure (mbar) 110 200

swirl 0.22

Momentum (N/MW) 4 8

RESULTS

(After 1 year operation)

HIGHER CLINKER QUALITY

KILN MORE STABLE

5 % LOWER SPECIFIC

CONSUMPTION

* Primary air % higher than usual for coal firing, as design is for fluff firing

TPI POLENE, Thailand, 3 Novaflam® 160 MW


RDF pipe (future)

TPI POLENE, Thailand, precalciner burner design


ZAOZHUANG Wofeng, China

KILN


PROD.(TPD) 5500

SEC. AIR (°C) 1100

FUELS COAL

BURNER REPLACEMENT TARGET DECREASE SPECIFIC CONSUMTION

ZAOZHUANG

WOFENG

China

(January 10)


ZAOZHUANG Wofeng, China

BEFORE AFTER

BURNER

TYPENanjing

designNOVAFLAM

PA (%) ? 12

PA pressure

(mbar)? 220

swirl 0,23

Momentum

(N/MW)? 8

CONFIRMED RESULTS

Lower specific consumption

(760 to 740 kcal/kg )

Higher production (5600 to 5700 tpd)

710

720

730

740

750

760

770

780

juin

-09

juil-

09

août

-09

sept

-09

oct-0

9

nov-

09

déc-

09

janv

-10

févr

-10

mar

s-10

avr-10

mai

-10

juin

-10

DATE

sp

ecif

ic c

on

su

mlt

op

n(

kcal/

kg

)

5450

5500

5550

5600

5650

5700

5750

kiln output (TPD) & spec.consumption(kcal/kg)

SPECIFIC CONSUMPTION (kcal/kg) OUTPUT (TPD)

No

vafla

m c

om

mis

sio

nin

g


DALIAN Tianrui, China

KILN


PROD.(TPD) 5500

SEC. AIR (°C) 1000

FUELS COAL

BURNER REPLACEMENT TARGET INCREASE PRODUCTION

DALIAN Tianrui

China

(April 10)


DALIAN Tianrui, China

BEFORE AFTER

BURNER

TYPE ? NOVAFLAM

PA (%) ? 9,5

PA pressure

(mbar)? 210

swirl 0,25

Momentum

(N/MW)? 6,5

CONFIRMED RESULTS

5% Higher production

Less reducing condition

(yellow clinker has disappeared)

5000

5100

5200

5300

5400

5500

5600

5700

5800

5900

no

v-0

9

dé

c-0

9

jan

v-1

0

févr-

10

ma

rs-1

0

avr-

10

ma

i-1

0

juin

-10

juil-

10

ao

ût-

10

se

pt-

10

oct-

10

DATE

kiln

ou

tpu

t (T

PD

)

No

vafla

m c

om

mis

sio

nin

g


Combustion in rotary kilns & precalciners: conclusions

The NOVAFLAM burner is simple to adjust

The NOVAFLAM burner allows:

• a very high % of Alternative Solid Fuels

• minimum electric consumption


The NOVAFLAM burner : a lower Carbon assessment

CO2 emission ELECTRIC CONSUMPTION

SPECIFIC CONSUMPTION

Concentration can be increased

Electric Consumption: less15%

USE of higher BIOMASS FUEL %

Pressure can be reduced

Flow reduced

Electric Consumption: less 30/40%

SOLID FUEL

CONVEYING LINES

PRIMARY AIR FAN

CO2

Reduced

!

Consumed

electricity

Reduced!

Reduced (average 3 %)

CO2

CO2

Fives Pillard 35

With our warm thanks!

LR

Documents

Fives Pillard, leading engineers & suppliers of … · Fives Pillard 1 Novaflam® burner Return of experience Design criteria Fives Pillard, leading engineers & suppliers of combustion